04/09/12

Compressed Air Contamination in the Food Industry | News | Features 1 | Food Safety Tech

Tuesday, August 28, 2012 12:52 PM

Compressed Air Contamination in the Food Industry

Used in a broad range of applications in the food processing industry such as mixing of
ingredients, cutting, drying of product, transporting/ propelling product through processing
systems and packaging of final product, compressed air is an often overlooked source of
contamination in the food industry.
By Allan Fish, Parker Hannifin Corporation and Peter Froehlich, Peak Media
Compressed air is used in a broad range of applications in the food processing industry such as mixing of
ingredients, cutting, drying of product, transporting/ propelling product through processing systems and
packaging of final product. In many of these applications, compressed air is in direct contact or indirect contact
with food product and the impurities in the compressed air may contaminate the food product which can result
in change of color and taste, reduced shelf life, in addition to exposure to bacteria and other microorganisms
can result in product recalls.
Compressed air, which is generated on site by pulling in ambient air and compressing it, contains water vapor,
particulate matter (atmospheric air typically contains 140-150 million dirt particles/m3)1 oil vapor and droplets
and microorganisms such as bacteria, viruses, fungi and spores (atmospheric air can contain up to 100 million
microorganisms/m3)2 . In addition, compressed air will also contain liquid oil, oil aerosols and oil vapor which
leak in through worn seals, orifices and o-rings within the compressor. Since the compression process raises
the temperature of the air, the air is then cooled before use, which condenses water vapor into water aerosols
and droplets. Water in the compressed air can produce rust and corrosion in the piping which flakes off and is
carried downstream, potentially contaminating the food product. In addition, water condensate and warm
compressed air provides the ideal environment for microbiological growth, growth of bacteria, spores and mold.
More and more food processors employ the principles of HAACP (Hazard Analysis and Critical Control Point)
and a risk analysis, ISO 8573.1, FDA and other government regulations to ensure that the production areas and
personnel are maintained at an acceptable level with regards to food safety/ quality and sanitation. However, in
most facilities, compressed air is considered a utility that is as clean as the facilitys ambient air, however, it is
not. More importantly, the filtration systems that are employed are designed to protect process equipment from
large slugs of water, oil, rust and pipe scale with a nominal rating of 25 to 40 micron and are not capable of
removing submicron contaminates such as bacteria and other microorganisms.
If, the HACCP analysis risk analysis is pursued in detail, every location in which compressed air is used,
would be correctly identified as CCP or critical control point. This is true whether it comes in direct contact or
indirect contact with the food product.
Unfortunately, there are no standards or laws that exist that define a minimum acceptable level of cleanliness
(filtration specification) when compressed air is used in the manufacturing of food. As a result, most companies
devise their own internal compressed air quality standard or specification.
The most common standard that is used is the ISO8573.1-2010 in conjunction with section 6 of The Code of
Practice that was co-jointly developed by the British Compressed Air Society (BCAS)3 and the British Retail
Consortium (BRC)4 Section 6 of this Code defines 3 separate categories of compressed air as used in the food
industry.
Direct contact with food
Indirect contact with food or Noncontact, high risk
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Compressed Air Contamination in the Food Industry | News | Features 1 | Food Safety Tech

Non-contact no risk
The ISO specification for compressed air, ISO8573.1-2010 is presented below.

For direct contact applications, section 6 of The Code recommends a class rating of 1.2.1.
For indirect contact applications, a class rating of 1.2.1 is recommended
For non-contact, no risk applications, a class rating of 1.4.1 is recommended

It is possible to achieve these class ratings and air quality specifications if proper care is taken to select and
install high performance compressed air dryers and filter systems that are properly sized and installed in
strategic locations throughout the facility.
Most facilities have a large dryer installed in the compressor room which will achieve the -40F dew point
specification. These should be monitored periodically for performance to specification and maintained regularly.
However, most facilities do not have proper filtration installed at the critical control points.
In order to achieve the filtration specification as outlined above, it is necessary to install at least a two stage
filter system as close as possible to the point of use. If there is excessive condensate, a third stage, prefilter
stage should also be installed.
A typical system should consist of a first stage, high efficiency coalescing filter with a rating of at least 99.99
percent at 0.01 micron which provides the necessary protection to the second stage of filtration the sterile air
filter. A sterile air filter with an efficiency rating of at least 99.9999+% at 0.01 micron is necessary5 in order to
achieve the class 1 rating and safeguard food product from becoming exposed to bacteria and other microorganisms.
Sterile air filter systems should be manufactured in full compliance with FDA requirements and accepted by the
USDA/ FSIS for use in federally inspected meat and poultry plants.
Installing high efficiency sterile air filter systems at critical control points will ensure contaminate free food
product resulting in improved shelf life, reduced recalls, and enhanced food quality and safety.
References:
1. High Quality Compressed Air for the Food Industry, Parker-Hannifin Ltd. Industrial Division, Gateshead,
Tyne and Wear, England, Catalogue 1740004425_02:2010
2. High Quality Compressed Air for the Food Industry, Parker-Hannifin Ltd. Industrial Division, Gateshead,
Tyne and Wear, England, Catalogue 1740004425_02:2010
3. http://www.bcas.org.uk/
4. http://www.brc.org.uk/brc_home.asp.
5. Evans, Dr. David, A Study on the Efficiency of Balston Sterile Air Filters for Producing Commercially
Sterile Air, Parker Hannifin, Haverhill MA, Bulletin TI-935T: 2003.
Comments:
Thursday, August 30, 2012 by
Great article! The only thing missing is Air Quality Testing to ensure all filters, dryers, etc. are functioning as
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